Portable air conditioning apparatus

ABSTRACT

An air conditioning apparatus is provided with an air plenum in fluid communication with an air inlet and an air outlet. A fan moves air through the air plenum. An interchangeable air conditioning core is removably installed within the air plenum and interposed between the air inlet and air outlet such that air moving along an air pathway is forced to proceed through the interchangeable air conditioning core.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.13/150,610 filed Jun. 1, 2011, the contents of which are incorporatedherein by reference.

FIELD OF THE INVENTION

The present invention relates generally to an air conditioningapparatus, and more specifically, to a portable air conditioningapparatus.

BACKGROUND OF THE INVENTION

With the diminishing supply of fossil fuels and their associatedspiraling costs, more homes and businesses are using a portable airconditioning apparatus to provide heating, ventilating, humidifying,and/or purification of local air. It is beneficial for such a portableair conditioning apparatus to be easy to service and thermallyefficient.

BRIEF SUMMARY OF THE INVENTION

In accordance with one aspect of the present invention, an airconditioning apparatus comprises an exterior case comprising an airinlet and an air outlet and an air plenum disposed within the exteriorcase in fluid communication with the air inlet and air outlet anddefining a primary air pathway and an independent secondary air pathway.A fan communicates with the air inlet for moving air through the airplenum, and an interchangeable air conditioning core is removablyinstalled within the air plenum and interposed between the air inlet andair outlet such that air moving along the primary air pathway is forcedto proceed through the interchangeable air conditioning core. An airjacket extends at least partially between the exterior case and theinterchangeable air conditioning core, the air jacket being in fluidcommunication with the secondary air pathway.

In accordance with another aspect of the present invention, an airconditioning apparatus comprises an exterior case comprising an airinlet and an air outlet, and an air plenum disposed within the exteriorcase in fluid communication with the air inlet and air outlet anddefining a primary air pathway. A fan communicates with the air inletfor moving air through the air plenum, and an interchangeable airconditioning core is removably installed within the air plenum andinterposed between the air inlet and air outlet such that air movingalong the primary air pathway is forced to proceed through theinterchangeable air conditioning core. A removable access panel definesat least a portion of the air plenum, wherein an interior of saidinterchangeable air conditioning core is accessible by removing theaccess panel.

In accordance with another aspect of the present invention, an airconditioning apparatus comprises an exterior case comprising an airinlet and an air outlet, and an air plenum disposed within the exteriorcase in fluid communication with the air inlet and air outlet anddefining a primary air pathway. A fan communicates with the air inletfor moving air through the air plenum, and an interchangeable airconditioning core is removably installed within the air plenum andinterposed between the air inlet and air outlet such that air movingalong the primary air pathway is forced to proceed through theinterchangeable air conditioning core. A plurality of sources of thermalenergy are installed within the interchangeable air conditioning coresuch that air moving along the primary airflow pathway is heated by theplurality of sources of thermal energy, wherein the plurality of sourcesof thermal energy are removable from the air plenum together with theinterchangeable air conditioning core.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an example air conditioning apparatus.

FIG. 2 is a side sectional view taken along line 2-2 of FIG. 1.

FIG. 3 is an exploded, perspective view of the air conditioningapparatus of FIG. 1.

FIG. 4 is front view of an example air conditioning core.

FIG. 5 is a side sectional view taken along line 5-5 of FIG. 4.

FIG. 6 is side view of the air conditioning core of FIG. 4.

FIG. 7 is a side sectional view taken along line 7-7 of FIG. 6.

FIG. 8 is similar to FIG. 7, but shows another example air conditioningcore.

DESCRIPTION OF EXAMPLE EMBODIMENTS

Turning to FIGS. 1 and 2, reference numeral 10 refers to an exampleportable air conditioning apparatus. Air conditioning apparatus 10includes an exterior case 12, a conditioner core support 14 mountedinside exterior case 12 and an interchangeable air conditioning core 16removably installed by conditioner core support 14. In the variousexamples described herein, the air conditioning apparatus 10 can includea wide variety of systems configured to condition (i.e., heat, cool,humidify, purify, etc.) air in various manners. In various non-limitingexamples, as will be described herein, the air conditioning apparatusmight include any or all of a heater, cooler, filter, source ofultraviolet (UV) radiation, humidifier, ion generator, variousinterconnecting ducting, dampers/valves, etc. The various components ofthe air conditioning system can be provided together as a singleassembly that can be closely contained or even spread out through theair conditioning apparatus 10. Multiple air conditioning apparatuses 10can also be utilized together to achieve a desired effect.

Where possible, the various structural elements can be coupled togetherby a minimal number of fasteners and joints, such as by a minimal numberof screws or the like, projections received in slots, or other removableor even non-removable locking structure, for improved serviceability.Further, the air conditioning apparatus can include various otherelements, such as described in U.S. Pat. Nos. 6,327,427 and 7,046,918,and pending application U.S. Ser. No. 12/755,746, the contents of whichare incorporated herein by reference in their entirety.

Exterior case 12 can be a generally box-like structure including a frontwall 18, a rear wall 20, a top wall 22, a bottom wall 24 and side walls26, 28. An air inlet 30 is provided in rear wall 20 and an air outlet 32is provided in front wall 18. Air inlet 30 and air outlet 32 can becovered with protective grilles, respectively. In addition oralternatively, a filter 42 can be positioned in at least a partiallycovering relationship over air inlet 30 and/or air outlet 32. Forexample, the filter 42 may be attached to rear wall 20 with variousclips or fasteners, such as hook-and-loop style fasteners or the like.Filter 42 may be of conventional construction, for example fiberglass orequivalent material as is commonly used in furnace filters. In oneexample, the filter 42 can be a POLYTRON filter or similar.

Some or all of the walls, such as any of the front wall 18, top wall 22and bottom 24 wall may be integrally formed as a wrapper to which sidewalls 26, 28 are formed with or joined with sheet metal screws, rivets,and/or by other conventional methods of construction such as welding,brazing and the use of fasteners, such a projection received in a slot,or combinations of methods as is known in the art. In one example, thetop wall 22 and both side walls 26, 28 can be formed from a single sheetof material, which can be bent to define the top wall 22 and side walls26, 28. In addition or alternatively, the air conditioning apparatus canbe supported by one or more stationary or movable feet coupled to thebottom wall 24. In one example, shown optionally in phantom, the feetcan be rotatable wheels 118, such as casters. The bottom wall 24 caninclude recesses, through holes, or the like to allow the casters to beat least partially recessed into the bottom wall 24 such that the airconditioning apparatus can be positioned relatively closer to a floor orother supporting surface. In one example, the rotatable wheels 118 canbe coupled to the bottom wall 24 by mechanical fasteners, adhesives,welding, or even by a twist-lock arrangement.

Exterior case 12 generally encloses conditioner core support 14.Conditioner core support 14 can comprise a front mounting panel 52 and arear mounting panel 54. In addition or alternatively, front mountingpanel 52 may be spaced a distance from front wall 18, or may be directlyadjacent thereto. For example, the front wall 18 can include adecorative plastic panel coupled to the mounting panel 52. The frontmounting panel 52 can be secured to at least one of the top wall 22,bottom wall 24 and side walls 26, 28. In one example, front mountingpanel 52 can be formed together with the bottom wall 24 (or even the topwall 22), such as being made out of the same sheet of metal, and may bebent relative to the bottom wall 24 so as to be generally perpendicularto the bottom wall 24 to facilitate manufacturing. Alternatively, frontmounting panel 52 can be the same as the front wall 18. An aperture 58is provided in front mounting panel 52 about which can be mounted adeflector shield 60 for directing air towards air outlet 32. Thedeflector shield 60 can be visible from the exterior of the unit, andcan be colored or otherwise configured to be visually appealing.

In the shown example, the rear mounting panel 54 can be secured to oreven formed with the front mounting panel 52. In another example, therear mounting panel 54 can be secured to at least one of top wall 22,bottom wall 24 and side walls 26, 28 and can be spaced a distance fromrear wall 20. In one example, the rear mounting panel 54 can be coupledto the bottom wall 24 by a mechanical fastener, such as a screw, rivet,or the like, and/or can also utilize a projection received in a slot forimproved structural rigidity. In addition or alternatively, the rearmounting panel 54 can include at least one, such as a pair, of areinforcing braces 25 coupled to the bottom wall 24. In another example,rear mounting panel 54 can be formed together with the bottom wall 24(or even the top wall 22), such as being made out of the same sheet ofmetal, and may be bent relative to the bottom wall 24 so as to begenerally perpendicular to the bottom wall 24 to facilitatemanufacturing. In one example, all of the bottom wall 24, front mountingpanel 52, and rear mounting panel 54 can be formed from a single sheetof metal.

The space between rear mounting panel 54 and rear wall 20 of exteriorcase 12 can form an intake chamber 62. A fan 66 provides airflow intothe intake chamber 62. An interior space between the front and rearmounting panels 52, 54 can be further bounded by side panels 53 and aremovable access panel 55 (see FIG. 3) to form an air plenum 63. The airplenum 63 defines a primary air pathway extending between the air inlet30 and air outlet 32, as well as an independent secondary air pathway.The air conditioning core 16 is installed within the air plenum 63 andinterposed between the air inlet 30 and air outlet 32 such that airmoving along the primary air pathway is forced to proceed through theinterchangeable air conditioning core 16. The air conditioning core 16contains at least one air conditioning device arranged therein, suchthat air moving along the primary airflow pathway is conditioned by theat least one air conditioning device.

The air plenum 63, including the front and/or rear mounting panels 52,54, could be removably or non-removably coupled to the frame (i.e.,front wall 18, rear wall 20, bottom wall 24, etc.) in various manners,such as with sheet metal screws and/or by other conventional methods ofconstruction such as welding, brazing and/or the use of fasteners, sucha projection received in a slot, or combinations of methods as is knownin the art. The air plenum 63 is in communication with the fan 66 via atleast one aperture 64 for providing fluid communication between the fan66 and the air conditioning core 16. For example, the fan 66 can bemounted to the air plenum 63 about the aperture 64 for drawing air intoair conditioning apparatus 10 though air inlet 30 in rear wall 20 andforcing air out through the air conditioning core 16 (via aperture 58)and out the air outlet 32. Additionally, at least a portion of theairflow moving though the air plenum 63 can pass into the air jacket viathe openings 120. Alternatively, the fan 66 may be located proximate theair inlet 30, to draw air in through that opening and direct it throughthe intake chamber 62 and into the air conditioning core 16. Variousfans operated at various speeds can be used, including axial,centrifugal, cross-flow, etc.

The interchangeable air conditioning core 16 is removably installedwithin the air plenum 63. As described, the removable access panel 55can define at least a portion of the air plenum 63, such that removal ofthe access panel 55 can provide service access into the interior of theair plenum 63. The access panel 55 can be coupled to the conditionercore support 14 in various manners. In one example, the air plenum 63can hang onto the rear mounting panel 54 by one or moreprojection-in-slot fasteners, and/or can also be coupled to the rearmounting panel 54 by screws or other mechanical fastener(s).

Removal of the access panel 55 can provide service access to an interiorof said interchangeable air conditioning core 16, such as to repair,replace, or otherwise maintain an air conditioning device containedtherein. As shown in FIG. 3, removal of the access panel 55 can provideready access to the interior of the air plenum 63 so that theinterchangeable air conditioning core 16 can be easily removedtherefrom. In one example, shown schematically in phantom in FIG. 2, theremovable access panel 55 can be coupled to the interchangeable airconditioning core 16 such that removal of the removable access panel 55thereby causes removal of the interchangeable air conditioning core 16from said air plenum 63. Thus, the air conditioning core 16 can be atleast partially retained by the access panel 55, and removal of the airconditioning core 16 can be simplified. The air conditioning core 16 canalso be independently secured within the air plenum 63.

A conventional power cord 46 can extend from rear wall 20 for connectingthe electrical components within exterior case 12 to a conventional 110volt A.G. line. If desired, air conditioning apparatus may have a powercord strain relief or the like installed in the hole through which powercord 46 passes. In addition or alternatively, a variable thermostaticcontrol 50 can be mounted to either or both of the front wall 18 (shown)or even to the rear wall 20 (not shown). The variable thermostaticcontrol 50 can include analog and/or digital structure for adjusting anoperational characteristic of an air conditioning device, such as adesired temperature or operational range (i.e., relatively hotter orcooler) and/or fan speed (i.e., relatively faster or slower), and mayinclude various knobs, buttons, or other selector structure. In additionor alternatively, the thermostatic control 50 can include variouscircuitry, sensors, such as various temperature sensors, humiditysensor(s), etc., and/or timer(s). Similarly, the variable thermostaticcontrol 50 can include indicia or other indicator structure to provide avisual and/or audible display of the desired settings/selections.Input/output structure, which may be located at a convenient location(e.g., on the front or sides) may be electrically coupled but physicallylocated apart from control structure (e.g., circuitry, sensors, etc.)that may be located within the unit. Structure can be provided for avisual and/or audible display of service information, such as warnings,filter change notifications, air conditioning device replacmentnotifications, etc. Thermostatic control 50 communicates with theoperative components of the air conditioning apparatus, such as thethermal energy source(s) and/or fan(s), to control operation thereof. Anon-off switch (not shown) may be provided on front wall 18 or rear wall20, if desired. An automatic-mode or manual-mode switch (not shown) mayalso be provided on front wall 18 or rear wall 20, if desired. A switch(not shown) may also be provided to operate the fan without the airconditioning device(s), so as to provide only air circulation.

In one embodiment of the air conditioning apparatus 10, one or moretemperature sensors, which may also function as limit switches, can beprovided about the air conditioning core 16. A control temperaturesensor 67 can be located about, on, or in air conditioning core 16 tosense the air temperature inside the air conditioning core 16, such asin an embodiment where the air conditioning apparatus 10 includes asource of thermal energy (i.e., a heater). In one example, the controltemperature sensor 67 is disposed close to the rear mounting panel 54(or even the front mounting panel 52) adjacent where air enters (orexits) air conditioning core 16, and acts as a fan control switch. Inone example, the control temperature sensor 67 can be mounted on acircuit board 65 or the like. When the temperature in air conditioningcore 16 rises above a predetermined temperature detected by the controltemperature sensor 67, such as 110 degrees F., fan 66 is switched on.Delayed starting of fan 66 until after the thermal energy sources areenergized can be preferred such that cold air is not forced through airoutlet 32. The control temperature sensor 67 can act in reverse at theend of a heating cycle when air conditioning apparatus is shut off. Inthis mode, fan 66 continues to operate until the temperature drops belowa predetermined temperature, such as 110 degrees F., improving theefficiency of the air conditioning apparatus by extracting residualheat.

A first temperature sensor 69 can be located to sense the airtemperature inside the air conditioning core 16 at a different locationthan the control sensor 67 and can function as a safety switch or fuse.The first temperature sensor 69 can be located towards the top of theair conditioning core 16 and can be retained by a bracket. When thetemperature in air conditioning core 16 rises above a firstpredetermined temperature detected by the first temperature sensor 69,such as 225 degrees F., the air conditioning device(s) (e.g., thermalenergy sources) can be shut down as a safety feature while said controltemperature sensor 67 keeps fan 66 running until the temperature in airconditioning core 16 falls below a predetermined temperature, such as110 degrees F. The first temperature sensor 69 can be provided as aswitch operable between on and off states, or as a one-time use fuse. Inaddition, a second temperature sensor 71 can also be provided to sensethe air temperature inside the air conditioning core 16 at a differentlocation than the first temperature sensor 69 and can function as anadditional safety switch or fuse. The second temperature sensor 71 couldbe located near the first temperature sensor 69, and could even beretained by the same bracket, or separately. When the temperature in airconditioning core 16 rises above a second predetermined temperaturedetected by the second temperature sensor 71, such as 250 degrees F.,the air conditioning device(s) (e.g., thermal energy sources) can beshut down as a safety feature while said control temperature sensor 67keeps fan 66 running until the temperature in air conditioning core 16falls below a predetermined temperature, such as 110 degrees F. Thesecond temperature sensor 71 can be provided as a switch operablebetween on and off states, or as a one-time use fuse. The secondpredetermined temperature can be different, such as greater than, thefirst predetermined temperature. In one example, it can be beneficial toelectrically couple the first and second temperature sensors 69, 71 in aseries configuration to provide a redundant safety scheme. It can alsobe beneficial to provide one of the first and second temperature sensors69, 71 as a switch, while the other is a fuse, though both can besimilar types. It will be apparent that the temperatures at which thetemperature sensors 67, 69, 71 operate are arbitrary and a matter ofdesign choice. Other sensors may be used that are triggered at differenttemperature levels, times, etc.

This spacing of air plenum 63 from exterior case 12 provides an airjacket 57 that extends at least partially about the air conditioningcore 16. The air plenum 63 can be supported at a distance below top wall22 and above bottom wall 24 of exterior case 12 and a distance from sidewalls 26, 28. The air jacket 57 is in fluid communication with thesecondary air pathway of the air plenum 63. In one example, the airjacket 57 can at least partially surround the air plenum 63. Air jacket57 can insulate the exterior case 12 to inhibit, such as prevent,overheating. In addition or alternatively, some or all of the interiorsurface(s) of the exterior case 12 can include an insulating material 59(shown schematically). For example, the interior surfaces of the topwall 22 and side walls 26, 28 can all include insulating material 59.

In addition or alternatively, the intake chamber and/or air plenum 63may form a portion of the air jacket 57, and/or can provide similarlyinsulating functionality. As such, it is possible for air conditioningapparatus to be safely operated with the exterior case 12 remaininggenerally cool to the touch, and/or with exterior case 12 fitted into awood cabinet or the like. In one example, the air jacket 57 can be influid communication with the air inlet 30 via at least one opening 120in the rear mounting panel 54 (and/or air plenum 63), and the air outlet32 via at least one opening 122 in the front mounting panel 52, toprovide a cooling airflow through the air jacket 57. The air plenum 63can be arranged in fluid communication with the opening(s) 120, 122 suchthat positive airflow from the fan 66 is caused to flow into and throughthe air jacket 57 during operation of the air conditioning apparatus.The airflow exiting the air jacket 57 via opening(s) 122 can proceedthrough at least one aperture 124. In one example, the aperture 124 canbe a gap, such as a ⅛″ clearance (or other dimension), located at theinterface between the front wall 18 and the front mounting panel 52 andin flow communication with the air outlet 32. The aperture 124 can beformed (e.g., molded or otherwise manufactured) into either or both ofthe front wall 18 and front mounting panel 52. Thus, airflow exiting theopening(s) 122 can proceed through the aperture 124 to allow the airfrom the air jacket 57 to join and mix with the conditioned (e.g.,heated) air exiting the air conditioning core 16 through air outlet 32.

As described herein, the air conditioning core 16 is installed withinthe air plenum 63 such that air moving along the primary air pathway isforced to proceed through the interchangeable air conditioning core 16.At least one air conditioning device is arranged within the airconditioning core 16, such that air moving along the primary airflowpathway is conditioned by the at least one air conditioning device. Awide variety of air conditioning devices can be provided to condition(i.e., heat, cool, humidify, purify, etc.) air in various manners. Invarious non-limiting examples, as will be described herein with laterreference to FIG. 8, the air conditioning device(s) might include any orall of a heater, cooler, filter, source of ultraviolet (UV) radiation,humidifier, ion generator, various interconnecting ducting,dampers/valves, etc. Various numbers and/or combinations of airconditioning devices can be used.

Turning now to FIGS. 4-7, an example air conditioning core 16 will bemore fully described. Air conditioning core 16 is removably mountedwithin the interior of the air plenum 63 and generally comprises an opentop 70, a curved bottom wall 72, side walls 74, and end walls 76. Thecurved bottom wall 72, side walls 74, and end walls 76 can be formedtogether from a single piece of metal through various bending and/ordeep draw methods, or can even be formed from a plurality of elementscoupled together. The air conditioning core 16 further includes one ormore flanges 75 (with or without seals) for installation within the airplenum 63. The air conditioning core 16 can be removably mounted withinthe air plenum 63 in various manners, including sheet metal screws,rivets, and/or by other conventional fasteners, such a projectionreceived in a slot, or combinations of methods as is known in the art.The air conditioning core 16 could be coupled to the access panel 55 forremoval therewith.

The air conditioning core 16 can have various geometries to guide theairflow therethrough. For example, the side walls 74 (and/or bottom wall72, end walls 76) can include inlet aperture(s) 85 to permit airflowinto the air conditioning core 16. It is understood that the aperture(s)85 can be provided in both of the side walls 74. Various numbers and/orgeometries of apertures 85 can be provided. Additionally, the air plenum63 can include a dividing wall 81 disposed between air inlet 30 and airoutlet 32. The dividing wall 81 can inhibit, such as prevent, fluidcommunication between the air inlet 30 and air outlet 32. However,dividing wall 81 can include one or more apertures 83 extendingtherethrough, and the air conditioning core 16 can be coupled to thedividing wall 81 with the open top 70 arranged in fluid communicationwith the aperture(s) 83. Thus, air moving along the primary air pathwayfrom the air inlet 30 and towards the air outlet 32 is forced to proceedinto the air conditioning core 16 via the apertures 85, and out of theair conditioning core 16 via the open top 70, in order to ultimatelyproceed through the dividing wall 81.

The example air conditioning core 16 will now be described with the airconditioning device including at least one source of thermal energy 78.For example, the source of thermal energy 78 can be an infrared emitter.Indeed, In the air conditioning core 16 shown in the drawings, mountingsfor two thermal energy sources 78 are provided with the energy sources78 being mounted horizontally and between side walls 74 (see FIGS. 5 and7). Horizontal mounting of energy sources 78 can be beneficial as thisarrangement improves serviceability of the air conditioning apparatus 10as will be further described.

Various example energy sources 78, such as radiant energy sources, canbe utilized. For example, each thermal energy source 78 can comprise ahigh resistance wire wrapped in a helical configuration. The helicallyconfigured element is suspended within a quartz tube. The tube is cappedwith ceramic end pieces or caps 80. The tube may be vacuum sealed andmay contain an inert gas. The quartz tube may be clear, semi-translucentor translucent. In a preferred embodiment, the thermal energy source 78is linear and has a clear quartz tube. In one example embodiment, eachof energy sources 78 is about 500 watts, where each source 78 drawsabout 4 amps. Thus, the total energy usage for operating the airconditioning apparatus is about 1000 watts so as to be operable on astandard household 110V A.G. outlet. Still, the thermal energy source 78can have various geometries, such as curved, polygonal, random, etc.

Each energy source 78 can be inserted into the air conditioning core 16via a hole 82 in the end walls 76, and can be supported within the airconditioning core 16 by a bracket 97 or the like. For example, thebracket 97 can be coupled to the bottom wall 72. One or more bracket(s)97 can support the energy sources 78 via their caps 80. A single bracket97 can support multiple energy sources 78, or multiple brackets 97 canalso be used. Either or both of the caps 80 can be adapted to retain thethermal energy source 78 mounted through the holes 82 in variousmanners, such as via a snap-lock arrangement or the like. Thus, each cap80 and source 78 can be designed to have a unique socket structure tofacilitate replacement of a source 78 by a repair technician or even bythe end-user. Electrically conductive wires can pass through the hole82, or may be provided to either of the end caps 80, for energizingenergy source 78. The electrically conductive wires can be pig-tailed atone end only to further facilitate the replacement of a source 78 by arepair technician or even by the end-user. For example, as shown in FIG.7, one of the end caps 80 can have an electrical plug 89 adapted to fitinto electrical socket structure to facilitate de-coupling each source78 for replacement.

In addition or alternatively, a retaining plate 86 can also be providedto positively couple the energy source 78 to the air conditioning core16. One end of the retaining plate 86 can be fit into a slot of the endwall 76. The one end of the retaining plate 86 can have a bent or curvedprofile to be coupled to the end wall 76 in a pivoting, cantileverfashion. For assembly, the energy source 78 can be inserted into thehole 82 in the end wall 76 of the air conditioning core 16 until one endcap 80 is received by the bracket 97. Next, the retaining plate 86 canbe pressed down against the other end cap 80 to secure the energy source78 to the end wall 76 of the air conditioning core 16. The retainingplate 86 can then be retained in place by removable coupling via amechanical fastener (e.g., screw, bolt, nut, etc.) or the like. In oneexample, a single mechanical fastener can be used. The electrical plug89 can remain accessible via the retaining plate 86 for connecting theelectrically conductive wires. Disassembly can be performed in reverse.Moreover, because each energy source 78 (and/or other air conditioningdevice) is coupled to the air conditioning core 16, the energy sources78 are removable from the air plenum 63 together as a modular unit withthe interchangeable air conditioning core 16. With such structure,individual energy sources 78 can be quickly and easily replaced withlittle disassembly and few fasteners, such as by only removing theaccess panel 55, air conditioning core 16, and the retaining plate 86,as well as providing easy manufacturing.

As shown in FIG. 7, the air conditioning core 16 can include a pluralityof sources of thermal energy 78. Due to space constraints, each of theenergy sources 78 can be arranged in a staggered formation. For example,the energy sources 78 can be vertically staggered so as to permit all ofthe energy sources 78 to be horizontally centered along the end walls76. The bracket 97 can be adapted accordingly. Moreover, the energysources 78 can at least partially overlap each other such that the airpassing through the air conditioning core and along the primary airflowpathway is heated by the plurality of energy sources 78.

The interchangeable air conditioning core 16 can be provided as a heatexchanger to increase the effectiveness of the plurality of energysources 78. For example, the air conditioning core 16 is preferably inthe form of a sheet of metal and fashioned into an enclosure around allof the sources of thermal energy source 78. Various metals can be used,such as steel, copper or aluminum that may or may not be pretreated. Inone example, the air conditioning core 16 can include an inner duct 90and an outer duct 92. As shown in FIG. 5, the inner duct 90 is disposedadjacent and surrounding the source(s) of thermal energy 78. The innerduct 90 is generally defined by the open top 70, curved bottom wall 72,side walls 74, and end walls 76. The inner duct 90 is further bounded bythe outer duct(s) 92.

One or more outer ducts 92 can be provided. The outer duct(s) 92 are influid communication with the apertures 85 extending through the sidewalls 74, such that air passing from the intake chamber 62 into the airplenum 63 passes through the apertures 85 and first through the outerduct 92 before entering the inner duct 90. Thus, the outer duct 92defines an intermediate pre-heating chamber 94 between the air plenum 63and the inner duct 90. The outer duct(s) 92 can be formed by a metalcasing enclosing the pre-heating chamber 94 while providing an outlet 96at a lower end. The outer duct 92 can be coupled to the side walls 74 invarious manners, such as with sheet metal screws and/or by otherconventional methods of construction such as welding, brazing and theuse of fasteners, such a projection received in a slot, or combinationsof methods as known in the art. The length of the outer duct 92 isgenerally shorter than the overall length of the side wall 74 such thatthere is a gap between the outlet 96 and the generally curved bottomwall 72 such that air exhausted from the outer duct 92 strikes thebottom wall 72 and is directed upwards past the sources of thermalenergy 78. For example, as shown in FIG. 2, such an arrangement of theinner and outer ducts 90, 92 can create a serpentine, circuitous“S”-shaped path for the airflow when viewed in cross-section.

In addition or alternatively, the bracket 97 supporting the energysources 78 can be adapted to direct the airflow, such as to impart aswirling motion to the air passing through the inner duct 90 and aroundthe energy sources 78. Upon being energized, energy sources 78 emit heatrays which are absorbed and reemitted by the inner and outer ducts 90,92 into the passing air. In addition or alternatively, the airconditioning apparatus described above can further increase the overallefficiency by positioning the energy sources 78 very close to the airoutlet 32, such that air heated by the energy sources 78 flows directlythrough open top 70 and out of the air outlet 32, with little if anyintermediate structure therebetween.

The outer duct 92 can be formed of various materials, though a materialwith a relatively higher heat transfer coefficient is preferable. Whenthe outer duct 92 is formed of copper material, the copper can bepretreated at temperature and for a time sufficient to soften the coppermaterial and to partially blacken the surface of the copper material. Inan example embodiment, the outer duct 92 can be formed from sheet copperhaving a thickness of 0.0216 inch and an oxygen content of 0.028% byweight. The outer duct 92 can be heated in an oven under ambientconditions for several hours at a temperature from about 850 degrees F.to about 900 degrees F. Any loose blackened material is removed by drybrushing. In one example, the outer duct 92 can be heated for two hoursat a temperature between about 850 degrees F. and 875 degrees F., afterwhich outer duct 92 is dry brushed and then further heated for one hourat 425 degrees F. It is believed that equally good results would beobtained when outer duct 92 is heated for three hours at 875 degrees F.and then dry brushed to remove any loose particles. Removal of looseparticles prevents them from being discharged when the air conditioningapparatus 10 is first operated. Pretreatment of the copper can improvethe heat efficiency of air conditioning apparatus by increasing theabsorptivity and emissivity of the outer duct 92 and roughening thewalls thereof for more turbulent air flow. Optionally, theaforementioned copper composition and heat treatment may also be appliedto interior of the inner duct 90. Still, some or all of the coppermaterial may not be pretreated.

When the outer duct 92 is formed of aluminum material, the aluminum canbe pretreated by anodizing. During the anodizing process, a clear filmof aluminum oxide is laid down on the aluminum's surface. For use in theair conditioning apparatus 10, the outer duct 92 is electrolyticallycolored a dark color to improve the material's radiant-heat properties,i.e., absorptivity and emissivity. It will be understood that the innerduct 90 may also be electrolytically colored. Still, either or both ofthe inner and outer ducts 90, 92 (or even additional elements) can beformed from various other materials, such as various metals (e.g.,steel), ceramics, etc. that may or may not be pretreated.

As shown in FIG. 2, the arrangement of the air conditioning core 16within the air plenum 63 forces air to be conditioned by moving alongthe primary air pathway to proceed through the inner and outer ducts 90,92. For example, cool air is first drawn into the intake chamber 62,passes into the air plenum 63, through the apertures 85 and the outerduct 92 and into the intermediate pre-heating chamber 94 to bepre-heated. The air then passes through the outlet 96 and is furtherheated by passage around the plurality of sources of thermal energy 78.The heated air then proceeds through the open top 70 and through thedividing wall 81 to be exhausted out of the air outlet 32. Thus, theprimary air pathway progressing through the air conditioning apparatus10 can include some or all of the following to progress from the airinlet 30, to the intake chamber 62 and air plenum 63, through theapertures 85 and inner and outer ducts 90, 92 of the air conditioningcore 16, along the length of the thermal energy source 78, through theopen top 70 and dividing wall 81, and out the air outlet 32.

Additionally, air also travels simultaneously by moving along theindependent secondary air pathway by proceeding into the intake chamber62 and through the air plenum 63. The air then moves through the opening120 into the air jacket 57 to further keep the exterior case 12 andcabinet relatively cool, and finally through the other opening 122 to beexhausted out of the aperture 124 adjacent the air outlet 32. Thus, theindependent secondary air pathway progressing through the airconditioning apparatus 10 can include some or all of the following toprogress from the air inlet 30, to the intake chamber 62 and air plenum63, through the opening 120 and into the air jacket 57, through theopening 122 and out the aperture 124 and/or air outlet 32.

In addition or alternatively, an auxiliary thermal energy source, suchas an infrared emitter (not shown), may be mounted adjacent front wall18 of exterior case 12 and front mounting panel 52 below air outlet 32.The auxiliary energy source can boost the temperature of the air passingout of air conditioning apparatus through air outlet 32. In addition,radiation from the auxiliary energy source can be reflected by copperdeflector shield 60 to provide a comforting warm glow seen throughgrille 34 over air outlet 32. It should be understood that deflectorshield 60 may also be formed of pretreated copper or aluminum but theglow through grille 34 may be somewhat compromised. In one embodiment ofair conditioning apparatus, auxiliary energy source can be a 250 wattquartz heating tube or other wattage.

In one example operation, thermostatic control 50 switches on energysources 78 (and auxiliary heater, if present) whenever the temperaturewithin the environment monitored by the thermostat drops below apredetermined minimum. Power is also supplied to fan 66 causing the fanto be activated. When control temperature sensor 67 is provided,activation of fan 66 may be delayed until the temperature in airconditioning core 16 has risen to a selected temperature. This is doneso that the air coming from air conditioning apparatus is warm onstartup.

A single air conditioning apparatus as described can effectively heat upto 500 square feet, or even more, and is capable of safely increasingthe temperature of the air drawn through the unit by approximately 120degrees F. It is believed the thermal efficiency of air conditioningapparatus is affected by pretreatment of the inner and outer ducts 90,92. In the embodiments described above, it is believed the airconditioning apparatus is more thermally efficient than a space heaterwithout pretreatment. It is further believed that this improvementresults more heat from the same amount of power used. Other efficienciesmay result from stripping residual heat from air conditioning core 16 onshut down with high temperature limit switch and from the pathway of theair through inner and outer ducts 90, 92 which can increase the dwelltime of the air in air conditioning core 16. It will be apparent thatother design features discussed above also contribute to the spaceheater's thermal efficiency.

Turning now to the example shown in FIG. 8, the air conditioningapparatus 10 can include a wide variety of air conditioning devicesconfigured to condition (i.e., heat, cool, humidify, purify, etc.) airin various manners. Various non-limiting examples will be described. Itis understood that the air conditioning apparatus 10 can include variousnumbers and/or combinations of air conditioning devices. Multiple airconditioning apparatuses 10 can also be utilized together to achieve adesired effect. For clarity, the various air conditioning devices shownin FIG. 8 are illustrated schematically within the air conditioning core16.

In various examples, the air conditioning device can include an airheater (similar to the source of thermal energy 78 discussed herein, oreven other types of air heaters). The air conditioning device can alsoinclude an air cooler 102, such as a conventional compressor-drivencooler or piezoelectric cooler. Where an air cooler 102 is provided, theair conditioning core can include supporting structure such as acompressor, condenser, evaporator, water drain, etc.

In another example, the air conditioning device can include at least oneair filter 104 adapted to at least partially filter the air passingthrough the air conditioning core 16. Various filters can be used, suchas paper, foam, cotton, HEPA, electrostatic, activated-carbon, etc. Thefilter 104 can be a single-use disposable item, or can also be cleanableand non-disposable.

In yet another example, the air conditioning device can be a source 106of ultraviolet (UV) radiation to facilitate purifying the air passingthrough the air conditioning core 16. The source 106 of UV radiation canbe used alone, or in combination with a photocatalyst 108.Photocatalytic air purification occurs when airborne contaminantsphysically touch a catalyst in the presence of UV light. The moleculesof pollutants, odors, volatile organic compounds (VOCs), and/orbiological contaminants (e.g., mold spores, bacteria, viruses, etc.)that come in contact with the photocatalyst are reconfigured intonon-toxic elements. Ultraviolet radiation sources having an emissionwavelength of about 180 nm to about 450 nm are preferred. It can bebeneficial to utilize a source 106 of ultraviolet radiation that hasgermicidal emission wavelength equal to or greater than about 254 nm toavoid generating ozone (or an insignificant amount of ozone), and/or anaccumulation of undesirable substances on the photocatalyst 108.

In yet another example, the air conditioning device can include ahumidifier 110 that can utilize a water supply (not shown) to modify therelative humidity of the air passing through the air conditioningapparatus 10. For example, the humidifier can relatively increase thehumidity in the air stream. Various types of humidification can beutilized, including hot and cold methods of increasing humidity in theair stream. The humidifier 110 can utilize a re-fillable water supply orcould even be connected to a constant water supply line. Additionally,the humidifier 110 could be provided with a water drain, catch basin,etc. that can have a fixed volume or discharge hose. It is furthercontemplated that humidifier can relatively dcrease the humidity in theair stream. A conventional compressor-driven cooler dehumidificationsystem, or other similar types, can be used.

In still yet another example, the air conditioning device can include anion generator 112 (e.g., a negative ion generator or the like) that usesrelatively high voltage to ionize (electrically charge) air molecules.Airborne particles are attracted to the electrode in an effect similarto static electricity to remove such airborne contaminants from the airstream. The ion generator 112 can include a replaceable filter media orthe like.

Though not shown, the air conditioning core 16 can further providevarious supporting structures for the different air conditioning device,such as interconnecting ducting, dampers/valves, water inlets/outlets,power supplies, etc. Additionally, the various air conditioning devicescan be secured to the various walls or surfaces, or can be retained byvarious brackets, etc.

In addition to the foregoing, the air conditioning apparatus 10 caninclude additional sterilizing, anti-bacterial, and/or deodorizingconditioning of the air flow. The sterilizing, anti-bacterial, and/ordeodorizing feature can be used in addition or as an alterative to anyof the air conditioning devices. In one example, various portions of theair conditioning apparatus 10 can be coated with sterilizing,antibacterial, and/or deodorizing coating(s) to provide such additionalconditioning of the air flow. Sterilizing, antibacterial, and/ordeodorizing coating(s) can be applied about the air inlet 30 or airoutlet 32, such as to portions of the adjacent front or rear walls 18,20. For example, the coatings could be applied to one or more faces ofthe grille 34 placed over the air outlet 32, or even the intakegrate/grille about the air inlet 30. In another example, the filter 42arranged about the air inlet 30 can include the coating. The coatingscould even be applied to interior surfaces that contact the air flow(e.g., primary and/or secondary air pathways), such as within the airplenum 63, air conditioning core 16, and/or air jacket 57, etc.

Various sterilizing, antibacterial, and/or deodorizing coatings can beutilized. For example, the coatings can contain silver, titanium oxideand/or copper, though other elements can also be used. In one example,nano-silver can be used that is a resin composition containing silverparticles with a nano-particle size. The sterilizing, antibacterial,and/or deodorizing coatings can be applied variously, such as viachemical deposition or wet coating.

However, coatings may wear off over time to reduce the sterilizing,antibacterial, and/or deodorizing effectiveness. For example, the filter42 may be periodically removed from the air conditioning apparatus 10for cleaning by the user. It can be beneficial to provide the coatingsin such a fashion that they are long-lasting and resistant to beingremoved via physical contact and/or periodic cleaning, as well as beingefficient and cost-effective for manufacturing (e.g., using relativelyless nano-silver material). In one example, the nano-silver particlescan be incorporated into a sprayable media, such as a UV-curable ink.The ink could be a relatively clear ink so as not to alter the outwardappearance of the coated items, or could have various colors, surfacefeatures, etc. This modified UV-curable ink can then be sprayed orotherwise deposited onto the desired portions of the air conditioningapparatus 10, such as to the air inlet 32, air outlet 34 (e.g., grille34), air plenum 63, air conditioning core 16, and/or filter 42. Inparticular, the ink can be sprayed onto and throughout the filter 42,which can be an open-cell foam or the like. Next, the coated item withthe UV-curable ink can be exposed to UV radiation to thereby bepermanently cured. Using this method, the nano-silver particles will bedispersed throughout the cured ink, which permits the silver particlesto perform the sterilizing, antibacterial, and/or deodorizing function,while also protecting the silver particles from being removed over time.

It is understood that any portion of the air conditioning apparatus 10can be provided with the sterilizing, antibacterial, and/or deodorizingcoating. While the coating can be used to condition the air flow,similar coatings can also be applied to the various exterior surfaces ofthe air conditioning apparatus 10 that an end user may touch. Forexample, the coatings can be applied to the front wall 18, rear wall 20,top wall 22, side walls 26, 28, bottom wall 24, variable thermostaticcontrol 50, exterior surfaces about the air inlet 30 or air outlet 32,or even other surfaces.

The invention has been described with reference to the exampleembodiments described above. Modifications and alterations will occur toothers upon a reading and understanding of this specification. Examplesembodiments incorporating one or more aspects of the invention areintended to include all such modifications and alterations insofar asthey come within the scope of the appended claims.

What is claimed is:
 1. An air conditioning apparatus, comprising: anexterior case comprising an air inlet and an air outlet; an air plenumdisposed within the exterior case in fluid communication with the airinlet and air outlet; a fan communicating with the air inlet for movingair through the air plenum; an interchangeable air conditioning coreremovably installed within the air plenum and configured such that airis forced to proceed through the interchangeable air conditioning coreby operation of said fan; and an air jacket extending adjacent theexterior case and located between said exterior case and theinterchangeable air conditioning core, wherein air directed through theair jacket by operation of said fan does not pass through theinterchangeable air conditioning core.
 2. The air conditioning apparatusof claim 1, further comprising at least one air conditioning devicearranged within the interchangeable air conditioning core such that airmoving through said core is conditioned by the at least one airconditioning device, wherein the least one air conditioning device isremovable from the air plenum together with the interchangeable airconditioning core.
 3. The air conditioning apparatus of claim 2, whereinthe at least one air conditioning device comprises a source of thermalenergy.
 4. The air conditioning apparatus of claim 3, wherein the sourceof thermal energy is an infrared emitter.
 5. The air conditioningapparatus of claim 3, wherein the interchangeable air conditioning corecomprises a heat exchanger comprising an inner duct and an outer duct,the inner duct being disposed adjacent and surrounding the source ofthermal energy.
 6. The air conditioning apparatus of claim 5, whereinthe outer duct defines an intermediate space between the air plenum andthe inner duct.
 7. The air conditioning apparatus of claim 3, furthercomprising a first temperature sensor located to sense the airtemperature inside the air plenum, wherein the first temperature sensoris configured to disable operation of the source of thermal energy whenthe air temperature in said air plenum exceeds a first predeterminedtemperature.
 8. The air conditioning apparatus of claim 7, furthercomprising a second temperature sensor located to sense the airtemperature inside the air plenum, wherein the second temperature sensoris configured to disable operation of the source of thermal energy whenthe air temperature in said air plenum exceeds a second predeterminedtemperature that is greater than the first predetermined temperature. 9.The air conditioning apparatus of claim 8, wherein the first and secondtemperature sensors are electrically arranged in series.
 10. The airconditioning apparatus of claim 8, wherein the second temperature sensoris a single-use fuse.
 11. The air conditioning apparatus of claim 2,wherein the at least one air conditioning device comprises a source ofultraviolet radiation.
 12. The air conditioning apparatus of claim 2,wherein the at least one air conditioning device comprises a humidifier.13. The air conditioning apparatus of claim 2, wherein the at least oneair conditioning device comprises an ion generator.
 14. An airconditioning apparatus, comprising: an exterior case comprising an airinlet and an air outlet; an air plenum disposed within the exterior casein fluid communication with the air inlet and air outlet; a fancommunicating with the air inlet for moving air through the air plenum;an interchangeable air conditioning core having installed hterein an airconditioning device, said air conditioning core being removablyinstalled within the air plenum and configured such that air moving isforced to proceed through the interchangeable air conditioning core byoperation of said fan; and a removable access panel defining at least aportion of the air plenum, wherein an interior of said interchangeableair conditioning core is accessible by removing the access panel; saidremovable access panel being coupled to the interchangeable airconditioning core such that removal of the removable access panel causesremoval of the interchangeable air conditioning core from said airplenum.
 15. The air conditioning apparatus of claim 14, furthercomprising an air jacket extending adjacent the exterior case andlocated between said exterior case and the interchangeable airconditioning core.
 16. An air conditioning apparatus, comprising: anexterior case comprising an air inlet and an air outlet; an air plenumdisposed within the exterior case in fluid communication with the airinlet and air outlet; a fan communicating with the air inlet for movingair through the air plenum; an interchangeable air conditioning coreremovably installed within the air plenum and configured such that airis forced to proceed through the interchangeable air conditioning coreby operation of said fan; and a plurality of sources of thermal energyinstalled within the interchangeable air conditioning core such that airmoving through said core is heated by the plurality of sources ofthermal energy, wherein the plurality of sources of thermal energy areremovable from the air plenum together with the interchangeable airconditioning core.
 17. The air conditioning apparatus of claim 16,wherein each of the plurality of sources of thermal energy comprises aninfrared emitter.
 18. The air conditioning apparatus of claim 16,wherein the interchangeable air conditioning core comprises a heatexchanger comprising an inner duct and an outer duct, the inner ductbeing disposed adjacent and surrounding the plurality of sources ofthermal energy.
 19. The air conditioning apparatus of claim 18, whereinthe outer duct defines an intermediate pre-heating chamber between theair plenum and the inner duct.
 20. The air conditioning apparatus ofclaim 16, further comprising an air jacket extending at least partiallybetween the exterior case and the interchangeable air conditioning core,said air jacket being configured such that air passing therethrough byoperation of said fan does not pass through said air conditioning core.